Package with enlarged base

ABSTRACT

Various containers with an enlarged base for receiving a food item are provided. The containers may be formed from various sleeves for heating, browning, and crisping a food item. Blanks for forming such sleeves and containers also are provided. The blanks, sleeves, and/or containers may include a removable portion at least partially defined by a line of disruption.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of International Application No.PCT/US08/050578, filed Jan. 9, 2008, which claims the benefit of U.S.Provisional Application No. 60/964,655, filed Aug. 13, 2007, both ofwhich are incorporated by reference herein in their entirety.

TECHNICAL FIELD

The present invention relates to various blanks, constructs, and methodsfor heating, browning, and/or crisping a food item, and particularlyrelates to various blanks, constructs, and methods for heating,browning, and/or crisping a food item in a microwave oven.

BACKGROUND

There is a need for a package or other construct that facilitatestransportation and consumption of a food item therein. There also is aneed for such a package or other construct that enhances browning andcrisping of a food item in a microwave oven. There further is a need fora package or other construct that provides enhanced browning and/orcrisping of an irregular shaped food item and facilitates transportationand consumption of the food item.

SUMMARY

The present invention generally is directed to various blanks andsleeves, pouches, packages, and other constructs (collectively“constructs”) formed therefrom. The various constructs formed from theblanks feature an enlarged or widened base that may provide stabilityfor handling a food item within the construct. If desired, theconstructs may include one or more features that allow a consumer toaccess various portions of the food item therein as the food item isconsumed. Additionally, any of the constructs of the invention mayinclude features that enhance the browning and crisping of the food itemheated therein.

In one aspect, numerous blanks are contemplated by the invention. Eachblank generally comprises a plurality of adjoined panels. Each panel hasa first dimension extending in a first direction and a second dimensionextending in a second direction, where the first direction issubstantially perpendicular to the second direction. The plurality ofadjoined panels may include a main panel, a first minor panel joined tothe main panel, a second minor panel joined to the main panel, a majorpanel joined to the first minor panel, and an end panel. The main panel,the first minor panel, the second minor panel, and the major panel maybe joined respectively to one another along a plurality of respectivesubstantially parallel fold lines extending in the first direction. Theend panel may be joined to the main panel along a substantially arcuatefold line extending generally in the second direction. The end panel hasan end edge opposite the arcuate fold line. The second dimension of theend panel generally increases from the arcuate fold line to the endedge, such that the end panel has a generally flared shape. A microwaveenergy interactive element may overlie at least a portion of at leastone of the adjoined panels.

In one example, the end panel includes a pair of opposed side edges thatextend divergently from the arcuate fold line to the end edge. The endedge of the end panel may be substantially arcuate in shape, and in someexample, the end edge may be outwardly arcuate in shape.

In another example, the major panel is a first major panel, and theplurality of adjoined panels further includes a second major paneljoined to the second minor panel along a fold line extending in thefirst direction, a first partial end panel joined to the first majorpanel along a first curved fold line extending generally in the seconddirection, and a second partial end panel joined to the second majorpanel along a second curved fold line extending generally in the seconddirection.

The various blanks typically include a pair of opposed surfaces. Amicrowave energy interactive element may overlie at least a portion ofat least one of the adjoined panels on at least one of the opposedsurfaces. The microwave energy interactive element may comprise asusceptor, a foil, a segmented foil (i.e., a plurality of metal foilsegments), or any combination thereof. In one example, the microwaveenergy interactive element converts at least a portion of impingingmicrowave energy into thermal energy.

If desired, any of the various blanks of the invention may include aremovable portion defined at least partially by a line of disruption.The removable portion may include at least a portion of at least one ofthe first main panel, the second main panel, the first minor panel, andthe second minor panel.

In one example, the removable portion is defined at least partially by atransverse tear line extending in the second direction substantiallyacross the adjoined panels, an oblique tear line substantially abuttingthe transverse tear line, and a cutout adjacent to the oblique tearline. In one variation, the cutout extends inwardly from a firstperipheral edge of the blank extending in the second direction and atleast partially defines a tab adjacent to the first peripheral edge. Theoblique tear line may extend substantially between the tab and thetransverse tear line. In another variation, the cutout is disposeddistal from the first peripheral edge within at least one panel of theplurality of adjoined panels, and a pair of oblique tear lines mayextend convergently towards the cutout. In one example, a first obliquetear line extends substantially between the cutout and the transversetear line, and a second oblique tear line extends substantially betweenthe cutout and the first peripheral edge of the blank.

In another example, the removable portion is defined at least partiallyby a tear line extending in the second direction substantially acrossthe adjoined panels. The removable portion may include a graspingfeature extending from a first peripheral edge of the blank extending inthe first direction, and a cutout along a second peripheral edgeextending in the first direction opposite the first peripheral edge,such that the cutout is substantially opposite the grasping feature. Inone variation, the blank includes a second removable portion defined atleast partially by a second tear line extending in the second directionsubstantially across the adjoined panels. The second removable portionmay include a grasping feature extending from the first peripheral edgeof the blank and a cutout along the second peripheral edge opposite thegrasping feature.

In another example, the removable portion is defined at least partiallyby a tear line extending in the second direction substantially acrossthe adjoined panels, and the removable portion includes a graspingfeature defined at least partially by a line of disruption in the secondminor panel. In one variation, the line of disruption is a substantiallyarcuate slit including a pair of ends disposed substantially along thefold line adjoining the main panel and the second minor panel. The blankfurther may include a pair of tear lines in the main panel extendingdivergently from respective ends of the slit. In one embodiment, a firsttear line substantially abuts the transverse tear line and a second tearline substantially abuts an edge of the main panel extending in thesecond direction.

In another example, the removable portion is a first removable portionof a plurality of removable portions defined by a plurality of tearlines extending obliquely across at least a portion of least one of theplurality of adjoined panels. Each tear line has a first end and asecond end, at least one of which substantially abuts a peripheral edgeof the blank. In one variation, the peripheral edge includes a firstedge and a second edge extending in the first direction opposite oneanother, and at least one tear line of the plurality of tear linesextends substantially between the first edge and the second edge. Inanother variation, each tear line of the plurality of tear lines issubstantially parallel to each other tear line of the plurality of tearlines. In yet another variation, the plurality of tear lines includes atleast a first tear line, a second tear line, and a third tear line, andthe first tear line is spaced from the second tear line a distance thatis approximately equal to a distance between the second tear line andthe third tear line.

In another example, at least some of the fold lines adjoining the panelsare tear lines, and the removable portion is defined at least partiallyby a first tear line that adjoins a first pair of adjacent panels and asecond tear line that adjoins a second pair of adjacent panels. Theremovable portion may include at least one of the first minor panel, thesecond minor panel, the first major panel, the second major panel, andthe main panel. In one variation, a tab extends from an end of at leastone of the first minor panel and the second minor panel. In stillanother variation, the blank may include a foldable portion defined aleast partially by a fold line extending in the second directionsubstantially across at least one of the plurality of adjoined panels.

In another example, the removable portion is defined at least partiallyby a line of disruption initiating and terminating proximate a firstperipheral edge of the blank opposite the arcuate end edge. The line ofdisruption may comprise a cut line, a score line, a kiss cut line, aperforated line, a zigzag cut line, a zipper cut line, or anycombination thereof. In one variation, the removable portion includes atleast a portion of the main panel. In another variation, the line ofdisruption initiates and terminates along the first peripheral edge ofthe blank adjacent to the main panel. At least a portion of the line ofdisruption may extend into the end panel. The portion of the line ofdisruption that extends into the end panel may define a tab.

Any of the various blanks may be formed into a construct (e.g., asleeve) for heating, browning, and/or crisping a food item in amicrowave oven. The construct may comprise a first main panel and asecond main panel in an opposed configuration, and a first minor paneland a second minor panel in an opposed configuration. The first mainpanel, the second main panel, the first minor panel, and the secondminor panel are joined to the first main panel and the second main panelalong respective fold lines to define at least partially an interiorsurface. A microwave energy interactive element may overlie at least aportion of the interior surface. The microwave energy interactiveelement may comprise a susceptor, a foil, a segmented foil, or anycombination thereof.

The construct also includes a first end panel foldably joined to thefirst main panel. The first end panel includes a pair of opposed sideedges that generally extend divergently from the first main panel. Insome embodiments, the construct also may include a second end panelfoldably joined to the second main panel. The second end panel includesa pair of opposed side edges that may extend convergently (i.e., taperinwardly) from the second main panel.

In one configuration, the first end panel and the second end panel arein a substantially opposed, facing relationship. In this configuration,the construct resembles a sleeve with a pair of opposed, open ends. Thefirst end panel and the second panel may be adapted to be folded towardthe interior space in a generally superposed configuration. In doing so,the sleeve may be transformed into a container for holding the food itemin an upright configuration, with the superposed end panels serving asthe base of the container.

In one example of this variation, the first end panel includes anarcuate end edge that extends between the pair of opposed side edges ofthe first end panel. In another example, the second end panel includes asubstantially linear end edge that extends between the pair of opposedside edges of the second end panel. In yet another example, a lockingfeature extends from the substantially linear edge of the second endpanel, and the locking feature is adapted to be received within a slotin the first end panel. In this manner, the end panels are locked intoposition to support the food item more securely.

If desired, the construct may include a removable portion defined atleast partially by a line of disruption. The removable portion maycomprise at least a portion of at least one of the first main panel, thesecond main panel, the first minor panel, and the second minor panel. Invarious examples, the removable portion may comprise a removable portionof a blank from which the construct is formed, for example, the blanksdescribed above and others described herein and/or contemplated hereby.

In one example, the removable portion is defined at least partially by atransverse tear line extending substantially across at least one of theadjoined panels, an oblique tear line substantially abutting thetransverse tear line, and a cutout adjacent to the oblique tear line. Inone variation, the cutout extends inwardly from a first end of theconstruct and at least partially defines a tab. The tab may be disposedadjacent to the first end of the construct, and the oblique tear linemay extend substantially between the tab and the transverse tear line.In another variation, the cutout is disposed within at least one of thefirst main panel, second main panel, first minor panel, and second minorpanel distal from a first end of the construct.

In another example, the removable portion is defined at least partiallyby a transverse tear line extending substantially across each of thefirst main panel, the second main panel, first minor panel, and secondminor panel. The removable portion may include a grasping featureprojecting from at least one of the first main panel and the second mainpanel distal from the fold lines adjoining the respective main panel tothe first minor panel and the second minor panel. In one variation, theconstruct further includes a second removable portion adjacent to thefirst removable portion.

In a further example, the removable portion is defined at leastpartially by a transverse tear line extending substantially across atleast the first main panel and the second main panel. The removableportion includes a grasping feature defined by a line of disruption inthe second minor panel. In one variation, the line of disruption is aslit, and the slit defines a tab comprising a portion of the secondminor panel.

In still another example, the removable portion is defined at leastpartially by a line of disruption extending obliquely across at leastone of the first main panel, the second main panel, the first minorpanel, and the second minor panel.

In yet another example, at least one of the fold lines adjoining thefirst main panel, the second main panel, the first minor panel, and thesecond minor panel is a tear line, and the removable portion is definedby at least one tear line that adjoins at least one of the first mainpanel and the second main panel to at least one of the first minor paneland the second minor panel.

In another aspect, the removable portion is defined by a line ofdisruption initiating and terminating proximate a first end of at leastone of the adjoined panels. In one variation, the line of disruptioninitiates and terminates proximate the first end of the first mainpanel. The line of disruption may extend into the end panel and maydefine a tab.

If desired, the sleeve may be transformed into a container in which thefood item can be positioned in an upright configuration fortransportation and/or consumption. The container generally may include apair of opposed main panels, a pair of opposed minor panels joined tothe main panels along respective fold lines, and a pair of end panelscollectively defining an interior space. The end panels may be foldedtoward the interior space in a superposed configuration. The containermay be positioned in an upright configuration with the food item beingsupported by the end panels. If desired, the end panels may beconfigured to provide a base for the container that is larger than theopening, thereby providing greater stability of the container and thefood item or items therein.

The container may include one or more removable portions that allow auser to reduce the size of, or alter the shape of, the container. Theremovable portion may be separated from the remainder of the constructas the food item is consumed to allow greater access to the food item.The removable portion may comprise the removable portion of the sleevefrom which the container is formed, for example, as described herein orotherwise contemplated hereby.

Other features, aspects, and embodiments will be apparent from thefollowing description and accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The description refers to the accompanying drawings, in which likereference characters refer to like parts throughout the several views,and in which:

FIG. 1A is a schematic top plan view of a first side of an exemplaryblank according to various aspects of the invention;

FIG. 1B is a schematic top plan view of a second side of the blank ofFIG. 1A opposite the first side;

FIG. 1C is a schematic perspective view of the blank of FIGS. 1A and 1Bformed into a sleeve with two open ends, according to various aspects ofthe invention;

FIG. 1D is a schematic bottom plan view of the sleeve of FIG. 1C;

FIG. 1E is a schematic top plan view of the sleeve of FIG. 1C;

FIGS. 1F and 1G are schematic perspective views of the blank of FIGS. 1Aand 1B and sleeve of FIGS. 1C-1E formed into a container for carrying afood item therein, according to various aspects of the invention;

FIG. 1H is a schematic perspective view of the container of FIGS. 1F and1G with the removable portion partially separated from the container;

FIG. 2 is a schematic top plan view of a variation of the exemplaryblank of FIG. 1A, according to various aspects of the invention;

FIG. 3 is a schematic top plan view of yet another exemplary blankaccording to various aspects of the invention, including a removableportion defined by a transverse tear line;

FIG. 4 is a schematic top plan view of still another exemplary blankaccording to various aspects of the invention, including first andsecond removable portions defined by first and second transverse tearlines;

FIG. 5 is a schematic top plan view of another exemplary blank accordingto various aspects of the invention, including a removable portiondefined by a transverse tear line;

FIG. 6 is a schematic top plan view of still another exemplary blankaccording to various aspects of the invention, including a removableportion defined by a transverse tear line and a cutout for facilitatingremoval of the removable portion;

FIG. 7 is a schematic top plan view of yet another exemplary blankaccording to various aspects of the invention, including a removableportion defined by a transverse tear line and a cutout for facilitatingremoval of the removable portion;

FIG. 8 is a schematic top plan view of still another exemplary blankaccording to various aspects of the invention, including a plurality ofremovable portions defined by oblique tear lines;

FIG. 9 is a schematic top plan view of another exemplary blank accordingto various aspects of the invention including various panels joinedalong longitudinal tear lines, where one or more of such panels mayserve as a removable portion;

FIG. 10 is a schematic top plan view of another exemplary blankaccording to various aspects of the invention, including a removableportion defined by a line of disruption initiating and terminatingproximate an edge of the blank; and

FIG. 11 is a schematic top plan view of still another exemplary blankaccording to various aspects of the invention, without a removableportion.

DESCRIPTION

The present invention may be illustrated further by referring to thefigures. For purposes of simplicity, like numerals may be used todescribe like features. It will be understood that where a plurality ofsimilar features are depicted, not all of such features necessarily arelabeled on each figure. It also will be understood that variouscomponents used to form the blanks and constructs of the presentinvention may be interchanged. Thus, while only certain combinations areillustrated herein, numerous other combinations and configurations arecontemplated hereby.

FIG. 1A depicts an exemplary blank 100 according to various aspects ofthe present invention. The blank 100 includes a plurality of adjoinedpanels. In this and other examples of the invention discussed hereinand/or contemplated hereby, each of the various panels and the blankgenerally has a first dimension, for example, a length, extending in afirst direction, for example, a longitudinal direction, D1, and a seconddimension, for example, a width, extending in a second direction, forexample, a transverse direction, D2. It will be understood that suchdesignations are made only for convenience and do not necessarily referto or limit the manner in which the blank is manufactured or erectedinto a construct.

Still viewing FIG. 1A, the blank 100 includes a plurality of adjoinedpanels including a main panel 102, a first major panel 104 a, a secondmajor panel 104 b, a first minor panel 106, and a second minor panel108. The first minor panel 106 is joined to first major panel 104 aalong a longitudinal fold line 110. The main panel 102 is joined to thefirst minor panel 106 along a longitudinal fold line 112. The secondminor panel 108 is joined to the main panel 102 along a longitudinalfold line 114. The second major panel 104 b is joined to the secondminor panel 108 along a longitudinal fold line 116. Fold lines 110, 112,116 are substantially parallel and substantially equal in length, asindicated by L1. Fold line 114 is substantially parallel to fold lines110, 112, and 116, but is somewhat shorter in length, as indicated byL2.

The blank 100 includes partial end panels 118 a, 118 b respectivelyjoined to panels 104 a, 104 b along respective curved fold line segments120 a, 120 b. Each partial end panel 118 a, 118 b includes a respectiveend edge 122, 124 that extends in the second direction, a respectiveexterior edge 126, 128 that extends in the first direction between therespective fold line segment 120 a, 120 b and the respective end edge122, 124, and a respective interior edge 130, 132 that extends obliquelybetween the respective fold line segment 120 a, 120 b and the respectiveend edge 122, 124. Edges 130, 132 form respective angles A1, A2 withrespect to theoretical extensions of fold lines 110, 116 (shown withdashed lines in FIG. 1A), such that the respective width W1, W2 of eachpartial end panel 118 a, 118 b tapers or decreases from the respectivefold line segment 120 a, 120 b to the respective end edge 122, 124.Optionally, partial end panel 118 a includes a tab or other lockingfeature 134 extending from end edge 122.

The blank 100 also includes an end panel 136 joined to the main panel102 along a substantially arcuate fold line 138. In this example, theend panel 136 is somewhat lentiform in shape (i.e., shaped like abiconvex lens), with an outwardly arcuate end edge 140 opposite arcuatefold line 138. In this example, the end panel 136 is asymmetrical orflared in shape, with a pair of side edges 142, 144 that extenddivergently and obliquely from the endpoints of fold line 138 to theendpoints of end edge 140. However, more symmetrical end panels arecontemplated. Edges 142, 144 form respective angles A3, A4 with respectto theoretical extensions of fold lines 112, 114 (shown with dashedlines in FIG. 1A), such that the width W3 of the end panel 136 increasesfrom fold line 138 to end edge 140. In this example, angles A3 and A4are substantially equal. However, it is contemplated that angles A3 andA4 may differ. The end panel 136 includes a somewhat T-shaped slit 146substantially centered between side edges 142, 144. The slit 146 isgenerally configured to receive the locking feature 134.

In this and other aspects of the invention, it will be understood thatother shapes for the end panel 136 and various other panels arecontemplated. For example, any of the various panels may be oval,rectangular, square, diamond-shaped, trapezoidal, polygonal, or may beany other regular or irregular shape. It also is contemplated that foldline 138 and end edge 140 may have any suitable shape, for example,curved, V-shape, zigzag shape, or any other linear, curvilinear,symmetrical, or asymmetrical shape.

If desired, one or both of the first minor panel 106 and the secondminor panel 108 may include respective longitudinal fold lines 148, 150.Fold line 148 divides minor panel 106 into two sections or segments,each having a length L1. Fold line 150 divides minor panel 108 into twosections or segments having differing lengths, L1 and L2, therebydefining a cutout 152. The length of minor panel 106 is approximatelyequal to the length of the portion of minor panel 108 that lies betweenfold line 150 and fold line 116.

In this example, longitudinal fold lines 148, 150 are slightly offsetfrom the longitudinal centerline of respective panels 106, 108.Specifically, fold line 148 is slightly closer to fold line 112 and foldline 150 is slightly closer to fold line 114. By configuring the foldlines 148, 150 in this manner, when a construct 174 is formed from theblank 100 and substantially flattened by folding along fold lines 148,150, the endpoints of edge 140 do not extend beyond fold lines 110 and116 (best seen in FIGS. 1D and 1E). Likewise, tab 162 does not extendbeyond fold line 116. This allows for more efficient cutting of theblank 100 and more efficient packaging and shipping of the construct174. It will be understood that the precise positioning of fold lines148 and 150 will vary depending on the shape of end panel 136, thelength of edges 142, 144, 140, and angles A3, A4. Thus, in someembodiments, one or both of fold lines 158, 160 may be substantiallycentered or may be offset respectively towards fold lines 110, 112, 114,116.

Returning to FIG. 1A, the first minor panel 106 and the second minorpanel 108 optionally include one or more respective apertures 154, 156.In the example shown in FIG. 1A, aperture 154 is substantially circularin shape and is substantially centered between fold lines 110, 112.Likewise, aperture 156 is substantially circular in shape and issubstantially centered between longitudinal fold lines 114, 116.However, it will be understood that in this and other aspects of theinvention described herein and contemplated hereby, the number, shape,size, and positioning of such apertures may vary for a particularapplication depending on type of construct being formed from the blank,the food item to be heated therein or thereon, the desired degree ofbrowning and/or crisping, whether direct exposure to microwave energy isneeded or desired to attain uniform heating of the food item, the needfor regulating the change in temperature of the food item through directheating, and whether and to what extent there is a need for venting.

Still viewing FIG. 1A, the blank 100 includes a removable portion 158defined at least partially by a tear line or other line of disruption160 extending in the transverse direction across at least a portion ofpanels 102, 104 a, 104 b, 106, 108. The removable portion 158 includesan extension or tab 162 extending from the main panel 102 adjacent toperipheral edge 164 of the blank 100. An oblique tear line 166 extendsfrom the tab 162 towards, and may abut, tear line 160. In this example,the tab 162 is somewhat rounded in shape. However, it will be understoodthat, in this and other examples, the tab or extension may have anyshape as needed or desired. For example, the extension may be oval,rectangular, square, diamond-shaped, trapezoidal, polygonal, or anyother regular or irregular shape. Alternatively, the tear lines 160,166, cutout 152, and tab 162 may be omitted.

If desired, a microwave energy interactive element 168 may overlie atleast a portion of blank 100, as shown schematically by stippling inFIG. 1B. The microwave energy interactive element may define at least aportion of the interior surface of a construct 170, 182 formed from theblank 100, as shown schematically by stippling in FIGS. 1C-1H. In oneexample, the microwave energy interactive element comprises a susceptor.However, other microwave energy interactive elements, such as thosedescribed below, are contemplated for use with the invention.

Turning now to FIGS. 1C-1E, numerous sequences of steps may be used toform a sleeve or other construct according to the invention. In oneexample shown in FIG. 1C, the blank 100 may be folded along longitudinalfold lines 110, 112, 114, 116 and edges 170, 172 brought towards eachother to form a sleeve 174 having two open ends 176, 178 with a cavityor interior space 180 therebetween. As shown schematically in FIG. 1D,the first and second major panels 104 a, 104 b may be overlapped asneeded to form a second main panel 104, partial end panels 118 a, 118 bmay be overlapped as needed to form end panel 118, and fold linesegments 120 a, 120 b may be overlapped as needed to form fold line 120.The overlapped panels may be joined to one another using an adhesive orother suitable material or technique. In this configuration, the panels118, 136 are in a substantially opposed, facing relationship with theopposed side edges 142, 144 of end panel 136 extending divergently fromthe first main panel 102 and opposed side edges 130, 132 of end panel118 extending convergently from the second main panel 104.

It will be understood that, in some embodiments (not shown), the firstmajor panel 104 a (or simply “major panel”) may be dimensioned so thatno additional major panel (e.g., the second major panel 104 b) is neededto form the second main panel 104. In such an example, the major panel104 a may be folded over and glued to the respective minor panel using aglue flap or otherwise, such that the major panel 104 a would serve asthe second main panel 104. Further, it will be understood that althoughseveral exemplary blanks are illustrated herein, numerous other blanksmay be used to form a construct according to the invention. Thus, theinvention is not limited to blanks with the left-to-right arrangement ofpanels illustrated in the figures. Instead, a blank may have “leftmost”and “rightmost” panel (as viewed, for example, in the figures)comprising a main panel, a major panel, a minor panel, a glue flap, orany combination thereof.

The first minor panel 106 and second minor panel 108 form opposed sidewalls for the construct 170, which may be flattened partially (FIG. 1C)or substantially (FIGS. 1D and 1E) by folding inwardly along fold lines148, 150. The sleeve 174 includes a removable portion 158 comprising theremovable portion 158 of the blank 100.

To use the construct 170 according to one acceptable method, a food item(not shown) may be inserted through an open end 176 or 178, and theconstruct with the food item inside may be placed into a microwave oven(not shown). As the food item is heated, the susceptor 168 convertsmicrowave energy to thermal energy, which generally enhances thebrowning and/or crisping of the surface of the food item. Since manyfood items have a somewhat irregular shape, it is contemplated that inthis and other aspects of the invention, any of the panels, for example,the first main panel 102, the first major panel 104 a, or the secondmajor panel 104 b, may include one or more fold lines, score lines, cutlines, cut crease lines, or other lines of disruption along all or aportion of the length or width thereof to accommodate the contours ofthe particular food item heated therein and to bring the susceptor 168into closer proximity with the surface of the food item. Any steamgenerated during heating may be released through the open ends 176, 178of the sleeve 170 and/or through apertures 154, 156.

After the item is heated sufficiently, the user may remove the food itemand discard the construct 170. Alternatively, the user may fold endpanels 118 and 136 towards the interior 180 of the sleeve 170 to form acontainer or construct 182 having an open end 176 and a closed end 178,as shown in FIGS. 1F and 1G. Alternatively still, the closed end 178 maybe formed at other times.

The container 182 may be used to support the food item in an uprightconfiguration with the food item resting on the overlapped panels 118,136, which collectively serve as a base for the container 182. Thisprovides a convenient means for comfortably handling the heated fooditem. Tab 134 may be inserted into slit 146 to secure the end panels118, 136 in a locked configuration.

As best illustrated in FIG. 1G, the closed end or base 178 of thecontainer 182 is somewhat enlarged or widened relative to the open end176, causing the sides 102, 104 (comprising panels 102 a, 102 b, 104 ofblank 100) to bulge somewhat outwardly from the interior space 180. As aresult, the construct 182 may be able to accommodate various irregularshaped food items, for example, croissant sandwiches, baguettes,calzones, or any other item. Furthermore, by having a wider base, thecontainer 182 may be more stable when seated in an upright configurationon a surface. Such a shape also might be easier to grasp for some users.

As the food item is consumed, the construct 182 may begin to interferewith accessing the food item. If desired, the user may insert a fingeror other implement into cutout 152, grasp tab 162, and begin to separatethe removable portion 158 from the remainder of the construct 182 alongtear lines 160, 166, as shown in FIG. 1H. Further pulling results incomplete separation of the removable portion 158 from the construct 182,thereby allowing greater access to the food item therein.

It will be understood that while the exemplary blank 100 of FIGS. 1A and1B and the exemplary constructs 174, 182 of FIGS. 1C-1H include only oneremovable portion 158, any number and configuration of removableportions may be used in accordance with the invention. Additionally, itwill be understood that in this and other aspects of the invention, anytype of tear line or other line of disruption may be used to define theremovable portion. For example, the line of disruption may include ascore line, a cut line, a perforated line, kiss cut line, zigzag cutline, zipper cut line, any other suitable line of disruption, or anycombination thereof.

FIGS. 2-10 illustrate examples of blanks including other arrangements oftear lines, cutouts, and other features that define removable portions.Such arrangements of tear lines may be used with other blanks, asillustrated in U.S. Patent Application Publication No. US2007/0131742A1, U.S. Patent Application Publication No. US200710131743A1, U.S. Patent Application Publication No. US2007/0131744A1, U.S. Patent Application Publication No. US2007/0131745A1, U.S. Patent Application Publication No. US2007/0138247A1, and PCT Publication No. WO/2007/067705, each of which isincorporated by reference herein in its entirety.

The various blanks 200, 300, 400, 500, 600, 700, 800, 900, 1000 includefeatures that are similar to blank 100 shown in FIGS. 1A and 1B, exceptfor variations noted and variations that will be understood by those ofskill in the art. For simplicity, and not limitation, the referencenumerals of similar features are preceded in the figures with a “2”(FIG. 2), “3” (FIG. 3), “4” (FIG. 4), “5” (FIG. 5), “6” (FIG. 6), “7”(FIG. 7), “8” (FIG. 8), “9” (FIG. 9), “10” (FIG. 10) instead of a “1”.Such blanks may be used to form sleeves, containers, and otherconstructs according to the invention, as described in connection withFIGS. 1A-1H.

Viewing FIG. 2, the blank 200 is similar to the blank 100 of FIG. 1,except that cutout 252 extends substantially between tab 262 and foldline 216. Thus, minor panel 208 has an overall length L3 that is lessthan the length L4 of minor panel 206. Likewise, fold line 250 has alength L3 that is less than the length L4 of fold line 248. In someinstances, the larger cutout 252 may facilitate separation of theremovable portion 258 along tear lines 260, 266.

FIG. 3 schematically depicts another blank 300 according to variousaspects of the invention. The blank 300 includes a removable portion 358at least partially defined by a transverse line of disruption or tearline 360 extending across at least a portion of each of panels 302, 304a, 304 b, 306, 308. The removable portion 358 includes an extension ortab 362 that partially defines edge 372. In this example, the tab 362 issomewhat arcuate in shape. However, it will be understood that theextension may have any shape as needed or desired, such as thosedescribed above. Tear lines 366 a, 366 b extend from tab 362 andterminate proximate edge 364 and transverse tear line 360, respectively.Tear lines 366 a, 366 b cooperate with tab 362 to facilitate removal ofthe removable portion 358. The tab and tear lines may have any suitableshape and configuration.

The removable portion 358 also includes a cutout 384 that partiallydefines edge 370. In this example, cutout 384 is somewhat arcuate inshape. As with the tab, the cutout may have any suitable shape as neededor desired, which may or may not correspond to the shape or dimensionsof the tab. The removable portion 358 also includes a gluing area 386adjacent the cutout 384. In the blank 300 shown in FIG. 3, the gluingarea 386 is shaped somewhat like an arch or bridge. However, it will beunderstood that the gluing area may have any suitable shape as needed ordesired.

FIG. 4 schematically depicts another blank 400 according to variousaspects of the invention. In this example, the blank 400 includes afirst removable portion 458 a and a second removable portion 458 b, eachextending in the transverse direction. Each removable portion 458 a, 458b includes at least a portion of each of panels 402, 404 a, 404 b, 406,408. The first removable portion 458 a is joined to the second removableportion 458 b along a transverse tear line 460 a. The second removableportion 458 b is joined to the remainder of panels 402, 404 a, 404 b,406, 408 along a transverse tear line 460 b.

The first and second removable portions 458 a, 458 b each includerespective extensions or tabs 462 a, 462 b that partially define aperipheral edge 472 extending in the longitudinal direction. In thisexample, tabs 462 a, 462 b are substantially arcuate in shape. However,it will be understood that the extension may have any shape as needed ordesired, such as those described above. Tear lines 466 a, 466 b extendfrom and may cooperate with tab 462 a to facilitate removal of removableportion 458 a. Likewise, tear lines 466 c, 466 d extend from and maycooperate with tab 462 b to facilitate removal of removable portion 458b.

The first and second removable portions 458 a, 458 b each include arespective cutout 484 a, 484 b that partially define peripheral edge 470extending in the longitudinal direction. In this example, cutouts 484 a,484 b are substantially semi-circular or arcuate in shape. However,cutouts 484 a, 484 b may have any suitable shape as needed or desired,and may or may not correspond to the shape or dimensions of tabs 462 a,462 b. The removable portions 458 a, 458 b also include respectivegluing areas 486 a, 486 b adjacent to cutouts 484 a, 484 b. In thisexample, gluing areas 486 a, 486 b are shaped somewhat like an arch orbridge. However, the gluing areas may have any suitable shape as neededor desired.

FIG. 5 schematically depicts another blank 500 according to variousaspects of the invention. The blank 500 includes a removable portion 558defined at least partially by a transverse tear line 560 extendingacross a portion of each of panels 502, 504 a, 504 b, 506, 508.

The removable portion 558 includes a somewhat triangular tab 562extending from the main panel 502. In this example, tab 562 comprises atleast a portion of minor panel 508 and is defined by a somewhat arcuateor V-shaped cut line 588. However, it will be understood that thelocation and shape of tab 562 may vary for a particular application.Tear lines 566 a, 566 b extend from cut line 588 towards, and may abut,edge 564 and transverse tear line 560, respectively, and may cooperatewith tab 562 to facilitate removal of the removable portion 558.

FIG. 6 schematically depicts another blank 600 according to variousaspects of the invention. In this example, the blank 600 includes aremovable portion 658 defined at least partially by a transverse tearline 660 extending across at least a portion of panels 602, 604 a, 604b, 606, 608. The removable portion 658 includes a somewhat elongatecutout 652 in the first main panel 602 and the second minor panel 608terminating proximate to fold line 650. The portion of cutout 652 in thefirst main panel 602 is somewhat semi-circular in shape with an arcuategrasping edge 688. The portion of the cutout 652 in the second minorpanel 608 is generally rectangular or square in shape. Tear lines 666 a,666 b extend from edge 688 towards, and may abut, edge 664 andtransverse tear line 660, respectively, and cooperate with grasping edge688 to facilitate removal of the removable portion 658.

FIG. 7 schematically depicts another blank 700 according to variousaspects of the invention. The blank of FIG. 7 is similar to the blank ofFIG. 6, except that cutout 752 lies within the second minor panel 708and extends substantially between fold lines 714 and 750. The cutout 752is somewhat square or rectangular in shape with a substantially straightgrasping edge 788 substantially aligned with fold line 714.

FIG. 8 schematically depicts another blank 800 according to variousaspects of the invention. In this example, panels 802, 804 a, 804 b,806, 808 collectively form a plurality of removable portions comprisingtear strip sections 858 a, 858 b, 858 c, 858 d. In this example, eachsection 858 a, 858 b, 858 c, 858 d initiates at panel 804 a, extendsdiagonally across panels 806, 802, 808, and terminates at panel 804 b.However, it will be understood that any number of tear strip sectionsmay be used, and each of such tear strip sections may initiate andterminate at any panel, as needed or desired for a particularapplication.

In this example, section 858 a is joined to section 858 b along obliquetear line 860 a. Section 858 b is joined to section 858 c along anoblique tear line 860 b. Section 858 c is joined to section 858 d alongan oblique tear line 860 c. In this example, tear lines 860 a, 860 b,860 c are substantially parallel. However, other configurations may beused with the invention. The various tear strip sections 858 a, 858 b,858 c, 858 d and tear line segments 860 a, 860 b, 860 c are positionedso that when the blank 800 is formed into a sleeve or other construct(not shown), the terminus of one section and corresponding tear line isthe origin of the next. In this manner, a single, continuous tear stripmay be formed along a substantially continuous oblique tear line (notshown).

The blank 800 includes a tab 862 or other grasping feature thatfacilitates initiation of a tear along tear line 860 a. The tab 862 mayhave any suitable shape as desired. In this example, the tab 862 isshown as being a portion of the first major panel 804 a. However, thetab 862 may be a portion of any of the various other panels, forexample, panels 802, 806, 808, or 804 b.

FIG. 9 schematically depicts another blank 900 according to variousaspects of the invention. In this example, panels 902, 904 a, 904 b,906, 908 are joined along respective longitudinal tear lines 910, 912,914, 916.

Any one or more of panels 902, 904 a, 904 b, 906, 908 may serve as aremovable portion of the blank 900 or construct formed therefrom (notshown) by tearing at least partially along at least one of longitudinaltear lines 910, 912, 914, 916. For example, first major panel 904 a maybe separated at least partially from the remainder of the blank 900 bytearing along tear line 910. First minor panel 906 may be separated atleast partially from the remainder of the blank 900 by tearing alongtear line 910 and/or tear line 912. Main panel 902 may be separated atleast partially from the remainder of the blank 900 by tearing alongtear line 912 and/or tear line 914. Second minor panel 908 may beseparated at least partially from the remainder of the blank 900 bytearing along tear line 914 and/or tear line 916. Second major panel 904b may be separated at least partially from the remainder of the blank900 by tearing along tear line 916.

Tear lines 910, 912, 914, 916 also serve as fold lines in forming aconstruct (not shown). However, it is contemplated that the removableportion of the blank may be formed or defined by one or more lines ofdisruption that do not also serve as fold lines.

The first minor panel 906 and the second minor panel 908 includerespective extensions or tabs 962 a, 962 b that extend beyond panels902, 904 a, 904 b, such that the overall length L5 of each of minorpanels 906, 908 including respective extensions 962 a, 962 b is greaterthan the length L6 of panels 902, 904 a, 904 b (measured at the longestpoint). In this example, tabs 962 a, 962 b are somewhat semi-circular orobround in shape. However, numerous other shapes are contemplatedhereby, such as those described above. Either or both tabs 962 a, 962 bmay be grasped by a user to facilitate separation of the construct (notshown) along one or more of tear lines 910, 912, 914, 916 to gain accessto a food item (not shown) inside.

FIG. 10 schematically depicts still another blank 1000 according tovarious aspects of the invention. In this example, the main panel 1002includes a removable portion 1058 defined by a line of disruption 1090,for example, a tear line or an offset kiss cut line, that initiates andterminates along the peripheral edge 1064 of the blank 1000 along themain panel 1002. In the example illustrated in FIG. 10, the removableportion 1058 generally resembles an arrow with an arcuate tab orextension 1062 defined at least partially by a cut line or slit 1088adjacent to end panel 1036. The tab 1062 generally may be shaped tofacilitate separation of the removable portion 1058 from the main panel1002.

While the various blanks and constructs illustrated in FIGS. 1A-10include a removable portion, it will be understood that numerous blanksand constructs without a removable portion are contemplated by theinvention. For example, FIG. 11 schematically depicts a blank 1000similar to FIG. 10 without the removable portion 1058. A sleeve,container, or other construct (not shown) may be formed from the blank1100 in a manner similar to that described above. However, a containerformed from the blank 1100 would not include a removable portion definedby one or more lines of disruption. Thus, the user may need to removethe food item from the container when the food item becomes difficult toaccess. Alternatively, the user may manually tear and/or remove one ormore portions of the container to access the food item.

Numerous materials may be suitable for use in forming the various blanksand constructs of the invention, provided that the materials areresistant to softening, scorching, combusting, or degrading at typicalmicrowave oven heating temperatures, for example, at from about 250° F.to about 425° F. The particular materials used may include microwaveenergy interactive materials and microwave energy transparent orinactive materials.

For example, any of the various blanks or constructs of the presentinvention may include one or more features that alter the effect ofmicrowave energy during the heating or cooking of the food item. Forexample, the blank or construct may be formed at least partially fromone or more microwave energy interactive elements (hereinafter sometimesreferred to as “microwave interactive elements”) that promote browningand/or crisping of a particular area of the food item, shield aparticular area of the food item from microwave energy to preventovercooking thereof, or transmit microwave energy toward or away from aparticular area of the food item. Each microwave interactive elementcomprises one or more microwave energy interactive materials or segmentsarranged in a particular configuration to absorb microwave energy,transmit microwave energy, reflect microwave energy, or direct microwaveenergy, as needed or desired for a particular microwave heatingconstruct and food item.

The microwave interactive element may be supported on a microwaveinactive or transparent substrate for ease of handling and/or to preventcontact between the microwave energy interactive material and the fooditem. As a matter of convenience and not limitation, and although it isunderstood that a microwave interactive element supported on a microwavetransparent substrate includes both microwave interactive and microwaveinactive elements or components, such constructs are referred to hereinas “microwave interactive webs”.

The microwave energy interactive material may be an electroconductive orsemiconductive material, for example, a metal or a metal alloy providedas a metal foil; a vacuum deposited metal or metal alloy; or a metallicink, an organic ink, an inorganic ink, a metallic paste, an organicpaste, an inorganic paste, or any combination thereof Examples of metalsand metal alloys that may be suitable for use with the present inventioninclude, but are not limited to, aluminum, chromium, copper, inconelalloys (nickel-chromium-molybdenum alloy with niobium), iron, magnesium,nickel, stainless steel, tin, titanium, tungsten, and any combination oralloy thereof.

Alternatively, the microwave energy interactive material may comprise ametal oxide. Examples of metal oxides that may be suitable for use withthe present invention include, but are not limited to, oxides ofaluminum, iron, and tin, used in conjunction with an electricallyconductive material where needed. Another example of a metal oxide thatmay be suitable for use with the present invention is indium tin oxide(ITO). ITO can be used as a microwave energy interactive material toprovide a heating effect, a shielding effect, a browning and/or crispingeffect, or a combination thereof. For example, to form a susceptor, ITOmay be sputtered onto a clear polymer film. The sputtering processtypically occurs at a lower temperature than the evaporative depositionprocess used for metal deposition. ITO has a more uniform crystalstructure and, therefore, is clear at most coating thicknesses.Additionally, ITO can be used for either heating or field managementeffects. ITO also may have fewer defects than metals, thereby makingthick coatings of ITO more suitable for field management than thickcoatings of metals, such as aluminum.

Alternatively, the microwave energy interactive material may comprise asuitable electroconductive, semiconductive, or non-conductive artificialdielectric or ferroelectric. Artificial dielectrics comprise conductive,subdivided material in a polymeric or other suitable matrix or binder,and may include flakes of an electroconductive metal, for example,aluminum.

In one example, the microwave interactive element may comprise a thinlayer of microwave interactive material (generally less than about 100angstroms in thickness, for example, from about 60 to about 100angstroms in thickness) that tends to absorb at least a portion ofimpinging microwave energy and convert it to thermal energy (i.e., heat)at the interface with a food item. Such elements often are used topromote browning and/or crisping of the surface of a food item(sometimes referred to as a “browning and/or crisping element”). Whensupported on a film or other substrate, such an element may be referredto as a “susceptor film” or, simply, “susceptor”. Where the substrate isa blank, carton, or other construct including a plurality of panels, asusceptor may overlie all or a portion of one or more of the panels, asillustrated schematically in FIG. 1B, and may form at least a portion ofthe surface proximate the food item, as illustrated schematically inFIGS. 1C-1H. However, other microwave energy interactive elements, suchas those described herein, are contemplated for use with the invention.

For example, the microwave interactive element may comprise a foilhaving a thickness sufficient to shield one or more selected portions ofthe food item from microwave energy (sometimes referred to as a“shielding element”). Such shielding elements may be used where the fooditem is prone to scorching or drying out during heating. The shieldingelement may be formed from various materials and may have variousconfigurations, depending on the particular application for which theshielding element is used. Typically, the shielding element is formedfrom a conductive, reflective metal or metal alloy, for example,aluminum, copper, or stainless steel. The shielding element generallymay have a thickness of from about 0.000285 inches to about 0.05 inches.In one aspect, the shielding element has a thickness of from about0.0003 inches to about 0.03 inches. In another aspect, the shieldingelement has a thickness of from about 0.00035 inches to about 0.020inches, for example, 0.016 inches.

As still another example, the microwave interactive element may comprisea segmented foil, such as, but not limited to, those described in U.S.Pat. Nos. 6,204,492, 6,433,322, 6,552,315, and 6,677,563, each of whichis incorporated by reference in its entirety. Although segmented foilsare not continuous, appropriately spaced groupings of such segments mayact as a transmitting element to direct microwave energy to specificareas of the food item. Such foils also may be used in combination withbrowning and/or crisping elements, for example, susceptors.

Any of the numerous microwave interactive elements described herein orcontemplated hereby may be substantially continuous, that is, withoutsubstantial breaks or interruptions, or may be discontinuous, forexample, by including one or more breaks or apertures that transmitmicrowave energy therethrough. The breaks or apertures may be sizedand/or positioned to heat particular areas of the food item selectively.As stated previously, the number, shape, size, and positioning of suchbreaks or apertures may vary for a particular application depending ontype of construct being formed, the food item to be heated therein orthereon, the desired degree of shielding, browning, and/or crisping,whether direct exposure to microwave energy is needed or desired toattain uniform heating of the food item, the need for regulating thechange in temperature of the food item through direct heating, whetherand to what extent there is a need for venting, and numerous otherfactors.

It will be understood that the aperture may be a physical aperture orvoid in the material used to form the construct, or may be anon-physical “aperture”. A non-physical aperture may be a portion of theconstruct that is microwave energy inactive by deactivation orotherwise, or one that is otherwise transparent to microwave energy.Thus, for example, the aperture may be a portion of the construct formedwithout a microwave energy interactive material or, alternatively, maybe a portion of the construct formed with a microwave energy interactivematerial that has been deactivated. While both physical and non-physicalapertures allow the food item to be heated directly by the microwaveenergy, a physical aperture also provides a venting function to allowsteam or other vapors to be released from the food item.

It also may be beneficial to create one or more discontinuities orinactive regions to prevent overheating or charring of the construct. Byway of example, and not limitation, in the constructs 174, 182illustrated in FIGS. 1C-1H, panels 104 a and 104 b are overlapped toform the second main panel 104. When exposed to microwave energy, theconcentration of heat generated by the overlapped panels may besufficient to cause the underlying support, in this case, paperboard, tobecome scorched. As such, the overlapping portions of one or both ofpanels 104 a and 104 b may be designed to be microwave inactive, forexample, by forming these areas without a microwave energy interactivematerial or by deactivating the microwave energy interactive material inthese areas.

Further still, one or more panels, portions of panels, or portions ofthe construct may be designed to be microwave energy inactive to ensurethat the microwave energy is focused efficiently on the areas to bebrowned and/or crisped, rather than being lost to portions of the fooditem not intended to be browned and/or crisped or to the heatingenvironment.

As stated above, any of the above elements and numerous otherscontemplated hereby may be supported on a substrate. The substratetypically comprises an electrical insulator, for example, a polymer filmor other polymeric material. As used herein the terms “polymer”,“polymer film”, and “polymeric material” include, but are not limitedto, homopolymers, copolymers, such as for example, block, graft, random,and alternating copolymers, terpolymers, etc. and blends andmodifications thereof. Furthermore, unless otherwise specificallylimited, the term “polymer” shall include all possible geometricalconfigurations of the molecule. These configurations include, but arenot limited to isotactic, syndiotactic, and random symmetries.

The thickness of the film typically may be from about 35 gauge to about10 mil. In one aspect, the thickness of the film is from about 40 toabout 80 gauge. In another aspect, the thickness of the film is fromabout 45 to about 50 gauge. In still another aspect, the thickness ofthe film is about 48 gauge. Examples of polymer films that may besuitable include, but are not limited to, polyolefins, polyesters,polyamides, polyimides, polysulfones, polyether ketones, cellophanes, orany combination thereof. Other non-conducting substrate materials suchas paper and paper laminates, metal oxides, silicates, cellulosics, orany combination thereof, also may be used.

In one example, the polymer film comprises polyethylene terephthalate(PET). Polyethylene terephthalate films are used in commerciallyavailable susceptors, for example, the QWIKWAVE® Focus susceptor and theMICRORITE® susceptor, both available from Graphic PackagingInternational (Marietta, Ga.). Examples of polyethylene terephthalatefilms that may be suitable for use as the substrate include, but are notlimited to, MELINEX®, commercially available from DuPont Teijan Films(Hopewell, Va.), SKYROL, commercially available from SKC, Inc.(Covington, Ga.), and BARRIALOX PET, available from Toray Films (FrontRoyal, Va.), and QU50 High Barrier Coated PET, available from TorayFilms (Front Royal, Va.).

The polymer film may be selected to impart various properties to themicrowave interactive web, for example, printability, heat resistance,or any other property. As one particular example, the polymer film maybe selected to provide a water barrier, oxygen barrier, or a combinationthereof. Such barrier film layers may be formed from a polymer filmhaving barrier properties or from any other barrier layer or coating asdesired. Suitable polymer films may include, but are not limited to,ethylene vinyl alcohol, barrier nylon, polyvinylidene chloride, barrierfluoropolymer, nylon 6, nylon 6,6, coextruded nylon 6/EVOH/nylon 6,silicon oxide coated film, barrier polyethylene terephthalate, or anycombination thereof.

One example of a barrier film that may be suitable for use with thepresent invention is CAPRAN® EMBLEM 1200M nylon 6, commerciallyavailable from Honeywell International (Pottsville, Pa.). Anotherexample of a barrier film that may be suitable is CAPRAN® OXYSHIELD OBSmonoaxially oriented coextruded nylon 6/ethylene vinyl alcohol(EVOH)/nylon 6, also commercially available from HoneywellInternational. Yet another example of a barrier film that may besuitable for use with the present invention is DARTEK® N-201 nylon 6,6,commercially available from Enhance Packaging Technologies (Webster,N.Y.). Additional examples include BARRIALOX PET, available from TorayFilms (Front Royal, Va.) and QU50 High Barrier Coated PET, availablefrom Toray Films (Front Royal, Va.), referred to above.

Still other barrier films include silicon oxide coated films, such asthose available from Sheldahl Films (Northfield, Minn.). Thus, in oneexample, a susceptor may have a structure including a film, for example,polyethylene terephthalate, with a layer of silicon oxide coated ontothe film, and ITO or other material deposited over the silicon oxide. Ifneeded or desired, additional layers or coatings may be provided toshield the individual layers from damage during processing.

The barrier film may have an oxygen transmission rate (OTR) as measuredusing ASTM D3985 of less than about 20 cc/m²/day. In one aspect, thebarrier film has an OTR of less than about 10 cc/m²/day. In anotheraspect, the barrier film has an OTR of less than about 1 cc/m²/day. Instill another aspect, the barrier film has an OTR of less than about 0.5cc/m²/day. In yet another aspect, the barrier film has an OTR of lessthan about 0.1 cc/m²/day.

The barrier film may have a water vapor transmission rate (WVTR) of lessthan about 100 g/m²/day as measured using ASTM F1249. In one aspect, thebarrier film has a WVTR of less than about 50 g/m²/day. In anotheraspect, the barrier film has a WVTR of less than about 15 g/m²/day. Inyet another aspect, the barrier film has a WVTR of less than about 1g/m²/day. In still another aspect, the barrier film has a WVTR of lessthan about 0.1 g/m²/day. In a still further aspect, the barrier film hasa WVTR of less than about 0.05 g/m²/day.

Other non-conducting substrate materials such as metal oxides,silicates, cellulosics, or any combination thereof, also may be used inaccordance with the present invention.

The microwave energy interactive material may be applied to thesubstrate in any suitable manner, and in some instances, the microwaveenergy interactive material is printed on, extruded onto, sputteredonto, evaporated on, or laminated to the substrate. The microwave energyinteractive material may be applied to the substrate in any pattern, andusing any technique, to achieve the desired heating effect of the fooditem. For example, the microwave energy interactive material may beprovided as a continuous or discontinuous layer or coating includingcircles, loops, hexagons, islands, squares, rectangles, octagons, and soforth. Examples of various patterns and methods that may be suitable foruse with the present invention are provided in U.S. Pat. Nos. 6,765,182;6,717,121; 6,677,563; 6,552,315; 6,455,827; 6,433,322; 6,410,290;6,251,451; 6,204,492; 6,150,646; 6,114,679; 5,800,724; 5,759,418;5,672,407; 5,628,921; 5,519,195; 5,420,517; 5,410,135; 5,354,973;5,340,436; 5,266,386; 5,260,537; 5,221,419; 5,213,902; 5,117,078;5,039,364; 4,963,420; 4,936,935; 4,890,439; 4,775,771; 4,865,921; andRe. 34,683, each of which is incorporated by reference herein in itsentirety. Although particular examples of patterns of microwave energyinteractive material are shown and described herein, it should beunderstood that other patterns of microwave energy interactive materialare contemplated by the present invention.

The microwave interactive element or microwave interactive web may bejoined to or overlie a dimensionally stable, microwave energytransparent support (also referred to as “microwave transparentsupport”, “microwave inactive support” or “support”) to form at least aportion of the construct.

In one aspect, for example, where a rigid or semi-rigid construct is tobe formed, all or a portion of the support may be formed at leastpartially from a paperboard material, which may be cut into a blankprior to use in the construct. For example, the support may be formedfrom paperboard having a basis weight of from about 60 to about 330lbs/ream, for example, from about 80 to about 140 lbs/ream.

The paperboard generally may have a thickness of from about 6 to about30 mils, for example, from about 12 to about 28 mils. In one particularexample, the paperboard has a thickness of about 12 mils. Any suitablepaperboard may be used, for example, a solid bleached or solidunbleached sulfate board, such as SUS® board, commercially availablefrom Graphic Packaging International.

In another aspect, where a more flexible construct is to be formed, thesupport may comprise a paper or paper-based material generally having abasis weight of from about 15 to about 60 lbs/ream, for example, fromabout 20 to about 40 lbs/ream. In one particular example, the paper hasa basis weight of about 25 lbs/ream.

Optionally, one or more portions or sides of the various blanks or otherconstructs described herein or contemplated hereby may be coated withvarnish, clay, or other materials, either alone or in combination. Forexample, at least the side of the support that will form an exteriorsurface of a construct erected therefrom may be coated with a claycoating or other base coating. The coating may then be printed over withproduct advertising, images, price coding, any other information orindicia, or any combination thereof. The blank or construct may then beovercoated with a varnish to protect any information printed thereon.

Furthermore, the blanks or other constructs may be coated with, forexample, a moisture and/or oxygen barrier layer, on either or bothsides, such as those described above. Any suitable moisture and/oroxygen barrier material may be used in accordance with the presentinvention. Examples of materials that may be suitable include, but arenot limited to, polyvinylidene chloride, ethylene vinyl alcohol, DuPontDARTEK™ nylon 6,6, and others referred to above.

Alternatively or additionally, any of the blanks or other constructs ofthe present invention may be coated or laminated with other materials toimpart other properties, such as absorbency, repellency, opacity, color,printability, stiffness, or cushioning. For example, absorbentsusceptors are described in U.S. Provisional Application No. 60/604,637,filed Aug. 25, 2004, and U.S. Patent Application Publication No. US2006/0049190 A1, published Mar. 9, 2006, both of which are incorporatedherein by reference in their entirety. Additionally, the blanks or otherconstructs may include graphics or indicia printed thereon.

It will be understood that with some combinations of elements andmaterials, the microwave interactive element may have a grey or silvercolor that is visually distinguishable from the substrate or thesupport. However, in some instances, it may be desirable to provide aweb or construct having a uniform color and/or appearance. Such a web orconstruct may be more aesthetically pleasing to a consumer, particularlywhen the consumer is accustomed to packages or containers having certainvisual attributes, for example, a solid color, a particular pattern, andso on. Thus, for example, the present invention contemplates using asilver or grey toned adhesive to join the microwave interactive elementsto the substrate, using a silver or grey toned substrate to mask thepresence of the silver or grey toned microwave interactive element,using a dark toned substrate, for example, a black toned substrate, toconceal the presence of the silver or grey toned microwave interactiveelement, overprinting the metallized side of the web with a silver orgrey toned ink to obscure the color variation, printing thenon-metallized side of the web with a silver or grey ink or otherconcealing color in a suitable pattern or as a solid color layer to maskor conceal the presence of the microwave interactive element, or anyother suitable technique or combination thereof.

In the examples shown herein, the construct is somewhat rectangular inshape, suitable, for example, for heating a sandwich or breakfast pastrytherein. However, it will be understood that in this and other aspectsof the invention described herein or contemplated hereby, numeroussuitable shapes and configurations may be used to form the variouspanels and, therefore, constructs. Examples of other shapes encompassedhereby include, but are not limited to, polygons, circles, ovals,cylinders, prisms, spheres, polyhedrons, and ellipsoids. The shape ofeach panel may be determined largely by the shape of the food item, andit should be understood that different packages are contemplated fordifferent food items, for example, sandwiches, pizzas, French fries,soft pretzels, pizza bites, cheese sticks, pastries, doughs, and soforth. The construct may be flexible, semi-rigid, rigid, or may includea variety of components having different degrees of flexibility.Likewise, the construct may include gussets, pleats, or any otherfeature needed or desired to accommodate a particular food item and/orportion size. Additionally, it will be understood that the presentinvention contemplates blanks and constructs for single-serving portionsand for multiple-serving portions.

Although certain embodiments of this invention have been described witha certain degree of particularity, those skilled in the art could makenumerous alterations to the disclosed embodiments without departing fromthe spirit or scope of this invention. All directional references (e.g.,upper, lower, upward, downward, left, right, leftward, rightward, top,bottom, above, below, vertical, horizontal, clockwise, andcounterclockwise) are used only for identification purposes to aid thereader's understanding of the various embodiments of the presentinvention, and do not create limitations, particularly as to theposition, orientation, or use of the invention unless specifically setforth in the claims. Joinder references (e.g., joined, attached,coupled, connected, and the like) are to be construed broadly and mayinclude intermediate members between a connection of elements andrelative movement between elements. As such, joinder references do notnecessarily imply that two elements are connected directly and in fixedrelation to each other.

It will be understood that in each of the various blanks and traysdescribed herein and contemplated hereby, a “fold line” can be anysubstantially linear, although not necessarily straight, form ofweakening that facilitates folding therealong. More specifically, butnot for the purpose of narrowing the scope of the present invention, afold line may be a score line, such as lines formed with a blunt scoringknife, or the like, which creates a crushed portion in the materialalong the desired line of weakness, a cut that extends partially into amaterial along the desired line of weakness, and/or a series of cutsthat extend partially into and/or completely through the material alongthe desired line of weakness; or any combination of these features.

For example, one type of conventional tear line is in the form of aseries of cuts that extend completely through the material, withadjacent cuts being spaced apart slightly so that a nick (e.g., a smallsomewhat bridging-like piece of the material) is defined between theadjacent cuts for typically temporarily connecting the material acrossthe tear line. The nicks are broken during tearing along the tear line.Such a tear line that includes nicks can also be referred to as a cutline, since the nicks typically are a relatively small percentage of thesubject line, and alternatively the nicks can be omitted from such a cutline.

Furthermore, various exemplary blanks and constructs are shown anddescribed herein as having fold lines, tear lines, score lines, cutlines, kiss cut lines, and other lines as extending from a particularfeature to another particular feature, for example from one particularpanel to another, from one particular edge to another, or anycombination thereof. However, it will be understood that such lines neednot necessarily extend between such features in a precise manner.Instead, such lines may generally extend between the various features asneeded to achieve the objective of such line. For instance, where aparticular tear line is shown as extending from a first edge of a blankto another edge of the blank, the tear line need not extend completelyto one or both of such edges. Rather, the tear line need only extend toa location sufficiently proximate to the edge so that the removablestrip, panel, or portion can be manually separated from the blank orconstruct without causing undesirable damage thereto.

Accordingly, it will be readily understood by those persons skilled inthe art that, in view of the above detailed description of theinvention, the present invention is susceptible of broad utility andapplication. Many adaptations of the present invention other than thoseherein described, as well as many variations, modifications, andequivalent arrangements will be apparent from or reasonably suggested bythe present invention and the above detailed description thereof,without departing from the substance or scope of the invention as setforth in the following claims.

While the present invention is described herein in detail in relation tospecific aspects, it is to be understood that this detailed descriptionis only illustrative and exemplary of the present invention and is mademerely for purposes of providing a full and enabling disclosure of thepresent invention and to provide the best mode contemplated by theinventor or inventors of carrying out the invention. The detaileddescription set forth herein is not intended nor is to be construed tolimit the present invention or otherwise to exclude any such otherembodiments, adaptations, variations, modifications, and equivalentarrangements of the present invention.

1. A blank for forming a microwave heating construct, comprising: aplurality of adjoined panels, each panel of the plurality of adjoinedpanels having a first dimension extending in a first direction and asecond dimension extending in a second direction substantiallyperpendicular to the first direction, the plurality of adjoined panelsincluding a main panel, a first minor panel joined to the main panel, asecond minor panel joined to the main panel, and a major panel joined tothe first minor panel, wherein the main panel, the first minor panel,the second minor panel, and the major panel are joined respectively toone another along a plurality of respective substantially parallel foldlines extending in the first direction, and an end panel joined to themain panel along a substantially arcuate fold line extending generallyin the second direction, wherein the end panel has an end edge oppositethe arcuate fold line, and the second dimension of the end panelincreases from the arcuate fold line to the end edge; and a microwaveenergy interactive element overlying at least a portion of at least oneof the adjoined panels.
 2. The blank of claim 1, wherein the end panelincludes a pair of opposed side edges that extend divergently from thearcuate fold line to the end edge.
 3. The blank of claim 1, wherein theend edge is substantially arcuate in shape.
 4. The blank of claim 3,wherein the end edge is outwardly arcuate in shape.
 5. The blank ofclaim 1, wherein the major panel is a first major panel, and theplurality of adjoined panels further includes a second major paneljoined to the second minor panel along a fold line extending in thefirst direction, a first partial end panel joined to the first majorpanel along a first curved fold line extending generally in the seconddirection, and a second partial end panel joined to the second majorpanel along a second curved fold line extending generally in the seconddirection.
 6. The blank of claim 5, wherein the first partial end paneland the second panel each include an end edge opposite the respectivecurved fold line, and a side edge that extends convergently from therespective curved fold line to the respective end edge.
 7. The blank ofclaim 1, wherein the microwave energy interactive element comprises asusceptor, a foil, a segmented foil, or any combination thereof.
 8. Theblank of claim 1, wherein the microwave energy interactive element isoperative for converting at least a portion of impinging microwaveenergy into thermal energy.
 9. The blank of claim 1, further comprisinga removable portion including at least a portion of at least one of thefirst main panel, the second main panel, the first minor panel, and thesecond minor panel.
 10. The blank of claim 9, wherein the removableportion is defined at least partially by a transverse tear lineextending in the second direction substantially across the adjoinedpanels, an oblique tear line substantially abutting the transverse tearline, and a cutout adjacent to the oblique tear line.
 11. The blank ofclaim 10, wherein the cutout extends inwardly from a first peripheraledge of the blank extending in the second direction, the cutout at leastpartially defines a tab adjacent to the first peripheral edge, and theoblique tear line extends substantially between the tab and thetransverse tear line.
 12. The blank of claim 10, wherein the cutout isdisposed distal from the first peripheral edge within at least one panelof the plurality of adjoined panels.
 13. The blank of claim 9, whereinthe removable portion is defined at least partially by a tear lineextending in the second direction substantially across the adjoinedpanels, and the removable portion includes a grasping feature extendingfrom a first peripheral edge of the blank extending in the firstdirection, and a cutout along a second peripheral edge extending in thefirst direction opposite the first peripheral edge, the cutout beingsubstantially opposite the grasping feature.
 14. The blank of claim 13,wherein the removable portion is a first removable portion, the tearline is a first tear line, the grasping feature is a first graspingfeature, the cutout is a first cutout, and the blank further includes asecond removable portion defined at least partially by a second tearline extending in the second direction substantially across the adjoinedpanels, the second removable portion including a second grasping featureextending from the first peripheral edge of the blank, and a secondcutout along the second peripheral edge opposite the second graspingfeature.
 15. The blank of claim 9, wherein the removable portion isdefined at least partially by a tear line extending in the seconddirection substantially across the adjoined panels, and the removableportion includes a grasping feature defined at least partially by a lineof disruption in the second minor panel.
 16. The blank of claim 15,wherein the line of disruption comprises a substantially arcuate slitincluding a pair of ends disposed substantially along the fold lineadjoining the main panel and the second minor panel.
 17. The blank ofclaim 9, wherein the removable portion is a first removable portion of aplurality of removable portions defined at least partially by aplurality of tear lines, each tear line of the plurality of tear lineshas a first end and a second end, each tear line independently extendsobliquely across at least a portion of least one of the plurality ofadjoined panels, and at least one of the first end and the second end ofeach tear line of the plurality of tear lines substantially abuts aperipheral edge of the blank.
 18. The blank of claim 9, wherein at leastsome of the substantially parallel fold lines extending in the firstdirection are tear lines, and the removable portion is defined at leastpartially by a first tear line that extends in the first direction andadjoins a first pair of adjacent panels of the plurality of adjoinedpanels, and a second tear line that extends in the first direction andadjoins a second pair of adjacent panels of the plurality of adjoinedpanels.
 19. The blank of claim 18, wherein the first dimension of atleast one of the first minor panel and the second minor panel is greaterthan the first dimension of the main panel.
 20. The blank of claim 9,wherein the removable portion is defined at least partially by a line ofdisruption initiating and terminating proximate a first peripheral edgeof the blank opposite the arcuate end edge.
 21. The blank of claim 20,wherein at least a portion of the line of disruption extends into theend panel.
 22. A microwave heating construct, comprising: a first mainpanel and a second main panel in an opposed configuration; a first minorpanel and a second minor panel in an opposed configuration, the firstminor panel and the second minor panel being joined to the first mainpanel and the second main panel along respective fold lines to at leastpartially define an interior space; a microwave energy interactiveelement overlying at least a portion of at least one of the first mainpanel, second main panel, first minor panel, and second minor panel on aside of the respective panel facing the interior space; and a first endpanel foldably joined to the first main panel, the first end panelincluding a pair of opposed side edges that extend divergently from thefirst main panel.
 23. The construct of claim 22, further comprising asecond end panel foldably joined to the second main panel, the secondend panel including a pair of opposed side edges that extendconvergently from the second main panel.
 24. The construct of claim 23,wherein the first end panel and the second end panel are foldably joinedto the first main panel and the second main panel along respectivearcuate fold lines.
 25. The construct of claim 23, wherein the first endpanel and the second end panel are adapted to be folded toward theinterior space in a superposed configuration.
 26. The construct of claim23, wherein the first end panel includes an arcuate end edge thatextends between the pair of opposed side edges of the first end panel.27. The construct of claim 23, wherein the second end panel includes asubstantially linear end edge that extends between the pair of opposedside edges of the second end panel.
 28. The construct of claim 27,wherein a locking feature extends from the substantially linear edge ofthe second end panel, the locking feature being adapted to be receivedwithin a slot in the first end panel.
 29. The construct of claim 23,wherein the microwave energy interactive element comprises a susceptor,a foil, a segmented foil, or any combination thereof.
 30. The constructof claim 23, wherein the microwave energy interactive element isoperative for converting at least a portion of impinging microwaveenergy into thermal energy.
 31. The construct of claim 22, furthercomprising a removable portion including at least a portion of at leastone of the first main panel, the second main panel, the first minorpanel, and the second minor panel.
 32. The construct of claim 31,wherein the removable portion is defined at least partially by atransverse tear line extending substantially across at least one of theadjoined panels, an oblique tear line substantially abutting thetransverse tear line, and a cutout adjacent to the oblique tear line.33. The construct of claim 2, wherein the cutout extends inwardly from afirst end of the construct and at least partially defines a tab.
 34. Theconstruct of claim 32, wherein the cutout is disposed within at leastone of the first main panel, second main panel, first minor panel, andsecond minor panel distal from a first end of the construct.
 35. Theconstruct of claim 31, wherein the removable portion is defined at leastpartially by a transverse tear line extending substantially across eachof the first main panel, the second main panel, first minor panel, andsecond minor panel, and the removable portion includes a graspingfeature projecting from at least one of the first main panel and thesecond main panel distal from the fold lines adjoining the respectivemain panel to the first minor panel and the second minor panel.
 36. Theconstruct of claim 35, wherein the removable portion is a firstremovable portion, the transverse tear line is a first transverse tearline, the grasping feature is a first grasping feature, and theconstruct further includes a second removable portion adjacent to thefirst removable portion, wherein the second removable portion is definedat least partially by a second transverse tear line extendingsubstantially across each of the first main panel, the second mainpanel, first minor panel, and second minor panel, and the secondremovable portion includes a second grasping feature projecting from atleast one of the first main panel and the second main panel distal fromthe fold lines adjoining the respective main panel to the first minorpanel and the second minor panel.
 37. The construct of claim 31, whereinthe removable portion is defined at least partially by a transverse tearline extending substantially across at least the first main panel andthe second main panel, and the removable portion includes a graspingfeature defined by a line of disruption in the second minor panel. 38.The construct of claim 31, wherein the removable portion is defined atleast partially by a line of disruption extending obliquely across atleast one of the first main panel, the second main panel, the firstminor panel, and the second minor panel.
 39. The construct of claim 31,wherein at least one of the fold lines adjoining the first main panel,the second main panel, the first minor panel, and the second minor panelis a tear line, and the removable portion is defined by at least onetear line that adjoins at least one of the first main panel and thesecond main panel, and at least one of the first minor panel and thesecond minor panel.
 40. The construct of claim 31, wherein the removableportion is defined by a line of disruption initiating and terminatingproximate a first end of at least one of the adjoined panels.
 41. Theconstruct of claim 40, wherein the line of disruption includes a firstportion extending from the first end of at least one of the adjoinedpanels, a second portion extending obliquely from the first portion, anda third, arcuate portion.
 42. The construct of claim 41, wherein thearcuate portion of the line of disruption lies substantially within thefirst end panel.
 43. The construct of claim 42, wherein the arcuateportion of the line of disruption comprises a cut that defines a tab.